Need a pep talk/help: can't eliminate exhaust leak after 5 attempts Options

[DC_neun_vierzehn]

Thanks everyone.

The careful/light filing of the pipe ends and inside of the dog ears just about did the trick. I still detect an ever so slight air leak on one of the 4 HE pipes at the heads (zero leaks at the muffler).

I will try to get it perfect this weekend and may try the Permatex 81878 copper gasket maker on the copper rings (and/or annealing which I haven't tried yet).

[Eric_Ciampa]

I just wrapped up installation of headers. Same advice as others although I didn’t come close to the 23 Ft Lbs that was suggested. I only needed 14. I already had to deal with a stripped head bolt. Make sure surfaces are clean at the head. I annealed mine but a few good runs do the same thing. I needed to run and re-tighten a few times. So I would follow the advice and run it a few times and re-torquing each time.

[IronHillRestorations]

Before you torque the nuts at the heads, use a flashlight and make sure the exhaust pipes are centered on the copper gaskets. You probably can’t get all four to be perfectly centered, but make sure a pipe isn’t off the copper.

[nathanxnathan]

I have always quenched the gaskets in water after heating them red hot. It doesn't make a difference with copper if you quench them or let them cool slow as far as softness, but it takes off the oxides.

Another point is to match the amount of material you file off the face/top of the flange, taking the same amount off the top of the ears. It's possible to bottom out the ears before you get a seal at the face.